Construction module and a method for manufacturing said module

ABSTRACT

A construction module comprises at least one covering element, which comprises or is as such a heat transfer element. Each of the heat transfer elements is advantageously formed of upper and lower sheets connected to each other by multiple connecting seams. The space between the seams are then puffed out so that at least one conduit is defined by the connecting seams between the seams and said upper and lower sheets of the heat transfer element. The construction module may comprise also an insulating layer between the covering elements.

TECHNICAL FIELD OF THE INVENTION

The invention relates to a construction module and a manufacturing method for the module. In particular the invention relates to a construction module for example for buildings, roofs, walls, floors and noise barriers, where the module can be used for transferring heat.

BACKGROUND OF THE INVENTION

Different kinds of construction modules are nowadays broadly used for building constructions. The modules may have been devised for a certain purpose, such as functioning as a structural element or a supporting structure, as well as a protecting and insulating element. Also, different kinds of integrated modules are known, where the construction module has for example both the supporting structure and the insulation feature. Furthermore, a construction module is known from the prior art, where a solar energy collection mechanism has been integrated with the construction module for collecting thermal energy and thereby producing hot water for example for sanitary or heating purposes.

For example document WO 99/54671 discloses a panel for collecting solar energy, where the panel has a front plate exposed to solar radiation and a rear face adjacent to an insulating layer. A conduit network formed of pipes is inserted between the front plate and the insulating layer. In addition document US 2009/0178670 discloses another solar heat collecting panel consisting of a core and a core-joined outside lining, where flow-pipes are located under laminated-plate lining. Pipes are introduced into the heat system with help of headers.

Further, document WO 99/54670 discloses a construction module for a roof or a wall of a building, where the module has a solar heat collector system. The module comprises a cover part formed of two portions, which are connected with each another so that a space with fluid is provided between the portions. In addition, a separate collector mechanism is arranged in the space to collect thermal energy from the fluid.

There are, however, some disadvantages relating to the known prior art solutions. For example in order to provide a building with a heat collecting and/or transferring system a plurality of time consuming steps are needed. For example, the insertion process of the heat transferring pipes is time consuming, because first the pipes must be straightened and then arranged and fixed into the structure of the building, such as into the roof or the wall structure, and additionally covered by covering means, for instance by a glass cover. The pipes should also be connected to each other e.g. by joints. The greater the number of the joints the more vulnerable the system is for leaks. Furthermore, the heat collection area of the elements or modules according to the prior art is typically quite limited, because the pipe cannot be bent too sharply and because of the annular cross section shape of the pipes. The pipes should also be covered for protecting the pipes from any physical interactions, because otherwise the pipes might get broken. Moreover, the twisting pipes e.g. on a wall or a roof may be visually scrappy and annoying. Still, in addition, the pipes increase the mass of the structure (especially when they are filled with water or other heat transfer medium), whereupon the structure of the building should be strong enough and e.g. the span length of the supporting structure quite short in order to carry out the additional mass of the pipes.

SUMMARY OF THE INVENTION

An object of the invention is to alleviate and eliminate the problems relating to the known prior art. Especially the object of the invention is to provide a construction module, which can be used as a thermal collector in constructions, and which is easy, fast and inexpensive to manufacture and also easy and fast to install. Moreover a further object of the invention is to provide a construction module, which collects or emits and transfers thermal energy very effectively. Additionally, an object of the invention is to provide a construction module, which is rigid, durable and resistant e.g. to changing and demanding weather conditions and which can be used as a conventional construction module so that no additional structure changes such as strengthening are needed.

The objects of the invention can be achieved by the features of the attached independent claims.

The invention relates to a construction module according to claim 1. In addition, the invention relates to a manufacturing method of the module according to claim 9, a use of the module according to claim 13, and an arrangement according to claim 14.

According to a first embodiment, a construction module comprises a covering element, which comprises a heat transfer element, or advantageously the covering element is itself a heat transfer element. The heat transfer element advantageously comprises two sheets connected to each other by multiple connecting seams, such as weld seams. The space between at least two seams is manipulated in order to form a conduit between said seams so that heat transfer medium can be transferred in said conduit. That is to say the conduit is defined by the upper and lower sheets and the seams. The expanding is advantageously implemented by applying high pressure, such as hydraulic pressure, within the space between said connecting seams so that the pressure causes at least one of the sheets to reform, such as stretch or bend, and thereby expands the space and form of said conduit with a volume between the connecting seams and the sheets. This allows providing e.g. an arbitrary shape for the conduit very fast and in an easy way. The shape of the seams and thus also the conduit can be programmed e.g. into an automated laser welding machine, which can be used for automatically welding the shape of the programmed shape.

The sheets are advantageously metal sheets, whereupon they can be connected to each other advantageously by laser beam welding. According to another embodiment the sheets may be plastic sheets, whereupon they are advantageously connected to each other by hot sealing. It is to be noted that the invention is, however, not restricted to these materials but also other formable materials can be used, especially materials, which can be formed under high pressure and which are good heat conductors and weatherproof.

Advantageously the sheet and in particularly the outer sheet used in the element is painted black since the black surface will absorb (and also emit) heat radiation very efficiently. In addition the sheets are advantageously as thin as possible so that the forming of the conduit can be implemented by lower pressure. The pressure used for expanding the spaces and thereby for forming the conduits may be e.g. about 10-20 bar, the pressure depending on the material and thickness of the material used in the sheets. According to an exemplary embodiment the thickness of the metal sheet is about 0.5 mm, whereupon it conducts heat much faster than a thicker sheet. Also the weight of the construction module can be kept minimal when sheets as thin as possible are used as the covering elements.

According to an embodiment the surface area of the conduit on the surface of the heat transfer element is at least 60%, preferably at least 75% and even more preferably at least 90% of the surface area of the heat transfer element. According to an advantageous embodiment the covering element is itself a heat transfer element, whereupon the surface area of the conduit on the surface of the covering element is at least 60%, preferably at least 75% and even more preferably at least 90% of the surface area of the covering element.

According to an advantageous embodiment the conduits are adjacent to each other and separated from each other only by said connecting seams. It is especially to be noted that according to a very advantageous embodiment two adjacent conduits have a one common seam or weld. This provides huge advantages, such as the manufacturing is easy, fast and effective since one seam can provide borderline for two conduits at the same time. In addition, the waste space is minimized since there is no unused space between the conduits or seams, whereupon the collection surface area is maximal making the element very effective for heat collection or emission.

According to an embodiment the heat transfer element comprises an inlet and an outlet for the heat transfer medium, wherein said inlet is configured to be connectable with the outlet of the heat transfer element of another module or a heat transfer medium circulation of a larger system, and wherein said outlet is configured to be connectable with the inlet of the heat transfer element of another module or the heat transfer medium circulation. This provides clear advantages because the total area of the heat collecting surface e.g. of the construction, such as of a building, comprising plurality of modules can be increased easily just by connecting the modules to each other or separately to the heat circulation system of the construction.

If the modules are connected to each other the flow rate of the heat transfer medium in the conduits can also be increased because the total heat collecting area provided by the plurality of connected modules is so broad that otherwise the heat transfer medium may achieve its maximum temperature too early, i.e. before the end of the circuit or before the last module belonging to the circulation.

It is to be noted that according to an advantageous embodiment of the invention the construction module may comprise two covering elements, but also a thermally insulating layer between said covering elements (two-sided module). The insulating layer may comprise e.g. PUR (polyurethane), PIR (polyisocyanurate), EPS (expanded polystyrene) or mineral wool (comprising stone wool and glass wool), but also other advantageously extrudable insulating material can be used, such as XPS (extruded polystyrene). In an advantageous embodiment the insulating layer may be used both for thermal insulation as well as for attaching, such as bonding or gluing, the covering elements to each other and thereby forming the construction module. The insulating material (such as EPS and wool) should either be glued to the covering elements, or they (such as PIR and PUR) may have the ability to bond the covering elements when they are applied (such as injected or injection moulded) between the elements. In addition, it is also to be noted that either one or both covering elements may comprise the heat transfer element according to the invention.

The construction module as described in this document can advantageously be used as a conventional construction module in different arrangements, such as e.g. in buildings, roofs, walls, floors or noise barriers, but also in base structures of streets, paths and courtyards etc. areas, where the area should be cooled or heated. The construction module may be used for example below bedding sand of a paving, asphalt or other revetment, when the module having the heat transfer element only in one side can be used.

Advantageously the modules can be connected to a heat transfer circulation system of the arrangement, whereupon a controlling means may be used for controlling at least the flow rate in the conduits of the heat transfer element. The modules may also be connected to a heat transfer circulation system of another arrangement, such as the modules below the base structures of the streets or paths may be connected to the modules of walls or noise barriers exposed to solar radiation in order to collect thermal energy and use it for heating the streets or paths, for example. Again it is to be noted that the modules according to the present invention can be used both for heating and cooling. For example in the daytime the covering elements exposed to solar radiation may be used for collecting heat energy (absorbing solar heat radiation) and thereby for heating e.g. water of a hot water boiler, and at night the same elements can be used for cooling e.g. water of a cold water storage, whereupon the elements are emitting heat radiation to the ambient space.

If the construction module comprises the heat transfer element at other side, i.e. indoor of the building, the inside element can be used in the daytime e.g. for cooling purposes by circulating cold water from the cold water storage in the conduits of the inside elements. Again the inside elements can be used for heating purposes e.g. at night by circulating water from the hot water storage in the conduits of the inside element. Of course there can also be two or more separate circulation systems and a heat exchanger therein between. In addition, the cooling or heating mode can be controlled by the controlling means by manipulating the circulation direction between the inner/outer elements and cold/hot water storages. Moreover, the cooling and/or heating efficiency can also be controlled by the controlling means by adjusting the flow rate of the heat transfer medium in the conduits. The controlling means may be a part of a broader system for controlling e.g. the state of the intelligent building, such as temperatures of different rooms etc.

In addition to the above mentioned advantages the construction module according to the present invention offers also further benefits, namely the construction module having one or even two covering elements of the heat transfer elements makes the construction module very rigid and durable because of the unitary sheets used for the heat transfer elements and especially if the conduits are filled with essentially incompressible medium or fluid, such as liquid, like glycol or water or mixture of those. The rigidity may additionally be increased e.g. by increasing the pressure of the medium or fluid within the conduits. The modules are rigid but at the same time quite light, since no additional pipes are needed. Due to the rigidity or stiffness of the construction modules the span length of the structure of the arrangement, where the modules are used, can be made very long. In a very advantage embodiment the modules can be used as self-supporting modules, whereupon no additional supporting structures are even needed.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following the invention will be described in greater detail with reference to exemplary embodiments in accordance with the accompanying drawings, in which:

FIG. 1A is top view of an exemplary heat transfer element according to an advantageous embodiment of the invention,

FIG. 1B is a sectional view of the heat transfer element of FIG. 1A taken at line B-C of FIG. 1A.

FIG. 1C is a side view of the heat transfer element of FIG. 1A.

FIG. 2A is a top view of an exemplary heat transfer element according to an advantageous embodiment of the invention,

FIG. 2B is a side view of the heat transfer element of FIG. 2A.

FIG. 2C is a top view of an exemplary heat transfer element according to an advantageous embodiment of the invention.

FIG. 3 is a perspective view of an exemplary construction module according to an advantageous embodiment of the invention,

FIG. 4 is a perspective view of an exemplary construction module according to an advantageous embodiment of the invention, and

FIG. 5A is a perspective view of a building utilizing an exemplary construction module according to an advantageous embodiment of the invention

FIG. 5B is a perspective view of a paving area utilizing an exemplary construction module according to an advantageous embodiment of the invention.

DETAILED DESCRIPTION

FIGS. 1A-C illustrate a principle of an exemplary heat transfer element 100 (which may function as such also as a covering element) and a method for manufacturing it according to an advantageous embodiment of the invention. In the method two sheets 101, 102 are connected to each other by connecting seams 103 provided e.g. by laser welding. FIG. 1A illustrates a top view of the sheets (lower sheet 102 is below the upper 101) and lines 103 illustrate the connecting seams along which the sheets are welded together, as can be seen in FIG. 1B (sectional view of the element along the line B-C).

The small spaces 104 are formed between the adjacent seams when the sheets are connected to each other by multiple connecting seams. When high pressure is applied into the space between two seams, at least one of the sheets 101, 102 advantageously expands or puffs out, as is depicted in FIG. 1C, whereupon the expanded space 104 between the seams forms a conduit 104, which is limited by both the seams 103 and the sheets 101, 102. As can be seen in FIGS. 1A-1C the adjacent conduits are advantageously separated only by one seam 103. FIG. 1C is also a sectional view of the element 100 along the line B-C.

The heat transfer element 100 may comprise one shaped (e.g. winding or twisting) conduit 104, as is depicted in FIGS. 1A-1C, but also a plurality of separate conduits 104 ₁, 104 ₂, 104 ₃ can be provided into the one heat transfer element 100, as is illustrated in FIGS. 2A-2C. In addition it is to be noted that the shape of the line of the seams 103 can be arbitrary having e.g. straight and curved lines, whereupon the shape of the conduits can also be arbitrary. Depending on the layout of the conduits the element 100 may comprise either one inlet 105 and one outlet 106 for the heat transfer medium (as in FIG. 1A) or a plurality of inlets 105 and outlets 106. In addition the heat transfer element 100 may comprise a plurality of separate conduits 104 ₁, 104 ₂, 104 ₃, which may comprise a common connecting conduit 104 _(a) between the inlet and the conduits as well as a common connecting conduit 104 _(b) between the outlet and the conduits, as is illustrated in FIG. 2C. Further, high pressure used for forming the conduits can be applied via said inlet and/or outlet. According to an embodiment an additional hollow nozzle or the like may also be applied between the sheets 101, 102 and connecting seams 103 so that high pressure can be applied via the nozzle into the space 104.

FIG. 3 illustrates an exemplary construction module 110 according to an advantageous embodiment of the invention, where the construction module 110 comprises a covering element 111, 112, and where the first one is a heat transfer element 100. Between the covering elements 111, 112, there is arranged an insulation layer 113, which can be provided e.g. by extruding insulating material, such as e.g. polyurethane or EPS (expanded polystyrene) foam between the covering elements. According to an embodiment the insulating material can be used for attaching, such as gluing, the covering elements to each other via said insulating material in order to provide the construction module 110.

FIG. 4 illustrates another exemplary construction module 110 according to an advantageous embodiment of the invention, where both of the covering elements 111, 112 of the construction module are as such (or comprise two) the heat transfer elements 101 ₁, 101 ₂, whereupon one of the heat transfer elements 101 ₁ faces outside and the other heat transfer element 101 ₂ faces inside of the building (illustrated in FIG. 5) for example.

FIG. 5A illustrates an exemplary arrangement, such as a building 120 utilizing the construction modules 110 according to an advantageous embodiment of the invention. The arrangement may comprise construction elements 110 having the heat transfer element 100 either one side 100 ₁ and/or both sides 100 ₁, 100 ₂ of the element 100. The elements are advantageously connected to a controlling means 121 via pipes 123 ₁, 123 ₂. It is to be noted that the first pipe 123 ₁ between the controlling means 121 and the heat transfer module 100 is connected e.g. to the inlet 105 of the heat transfer module 100, whereupon the second pipe 123 ₂ between the controlling means 121 and the heat transfer module 100 is connected to the outlet 106 of the heat transfer module 100. In addition the inlets 105 and outlets 106 of the heat transfer modules 100 of the construction modules 110 can be connected to each other by intermediate pipes 123 ₃, whereupon a plurality of modules can be connected in series in order to provide a larger heat collecting or heat emitting area.

According to an embodiment the heat transfer medium circulation can be implemented (at least partly) based on gravity. However, the controlling means 121 may comprise e.g. an adjustable pump 122 by which the flow rate of the heat transfer medium within the conduits of the heat transfer elements can be managed. In addition, the controlling means 121 may be adapted to control the flow between the outer 100 ₁ and the inner 100 ₂ heat transfer elements and the hot 124 and the cold 124 water boilers or reservoirs for example based on the daytime and whether the cooling or heating mode is desired inside the building 120 or whether the water in the hot water boiler 124 should be heated by the solar thermal energy (circulating the heat transfer medium between the hot water boiler 124 and the outer heat transfer element 100 ₁) or whether the inside temperature of the building 120 should be cooled by the cold water of the reservoir 125 (circulating the heat transfer medium between the cold water reservoir 125 and the inner heat transfer element 100 ₂). It should be noted that the hot/cold water storages 124, 125 can be provided with heat exchangers 126.

Furthermore, according to an advantageous embodiment the heated medium can be fed to the outer heat transfer element 100 ₁ for example, if there is snow or ice on the surface of the construction module, such as on the module used on the roof of the building 120. This is an important and convenient feature especially in northern countries, because the snow or ice can be melted or dropped from the roof by supplying e.g. hot water to the conduits of the modules thereby preventing any accidents that the falling snow or ice might cause.

FIG. 5B illustrates another exemplary arrangement, where the modules of the invention can be utilized, namely a paving area 130. The modules 110 can advantageously be used in base structures of paths, such as below bedding sand 131 of the paving blocks 132. The paving area 130 can thus either be cooled or heated, for example, when the heat transfer element is connected to another heat circulation system.

Even though only a building and a paving are illustrated in FIGS. 5A and 5B as examples of the object where the modules of the invention can be used, it is to be understood that the modules can also be utilized similarly in other constructions, such as for example noise barriers located near residential areas or buildings to be heated and/or cooled, whereupon the heat circulation pipes are advantageously arranged between the heating/cooling system of the building and modules of the noise barriers by the side of the highways or railways, for example.

Furthermore it is to be noted that the modules of the invention can also be utilized in walls, roofs and/or other structures (such as racks and shelves) of cold-storage rooms or refrigerating rooms to cool the inner temperature of the room to +4° C. or even to −20-−30° C. There is even no need to paint the surfaces of the elements of the modules used in cold spaces, because the heat transfer elements are advantageously made of stainless steel or acid-proof steel, which is suitable as such for the hygienic surface of these kinds of spaces. Polyurethane can be used as an example of the insulating material of the modules used in the cold spaces.

The invention has been explained above with reference to the aforementioned embodiments, and several advantages of the invention have been demonstrated. It is clear that the invention is not only restricted to these embodiments, but comprises all possible embodiments within the spirit and scope of the inventive thought and the following patent claims. Especially it should be noted that the heat collection surface area of the heat transfer module may also be used as an emitting surface area e.g. during the night time and thereby for cooling depending on the heat medium circulation arranged in the system. In addition, it is to be noted that the heat transfer medium is advantageously uncompressible fluid, such as e.g. water or glycol or a mixture of those, but also pressurised gas or other medium suitable for transferring heat energy in an efficient and convenient way can be used. Further the heat transfer element may be covered (at least partly) by covering means, such as glass or plastic, in order to minimize heat convection or thermal radiation from the surface of the heat transfer element, especially when it is used for collecting solar thermal energy. 

1. A construction module comprising a covering element, wherein said covering element comprises a heat transfer element, and said heat transfer element comprises two sheets connected to each other by multiple connecting seams and said heat transfer element further comprises at least one conduit for a heat transfer medium, where said conduit is defined by said multiple connecting seams between said connecting seams and said sheets.
 2. A module according to claim 1, wherein the surface area of the conduit on the surface of the heat transfer element or covering element is at least 60%, preferably at least 75% and even more preferably at least 90% of the surface area of the heat transfer element or covering element.
 3. A module according to claim 1, wherein said sheets are metal or steel sheets and the connecting seams are formed by laser beam welding, or wherein said sheets are plastic sheets and the connecting seams are formed by hot sealing.
 4. A module according to claim 1, wherein the conduits are adjacent to each other and separated from each other only by said connecting seams.
 5. A module according to claim 1, wherein the heat transfer element comprises an inlet and an outlet for the heat transfer medium, and wherein said inlet is configured to be connectable with the outlet of the heat transfer element of another module or a heat transfer medium circulation, and wherein said outlet is configured to be connectable with the inlet of the heat transfer element of another module or the heat transfer medium circulation.
 6. A module according to claim 5, wherein the heat transfer element comprises one or more advantageously shaped conduits between said inlet and outlet.
 7. A module according to claim 1, wherein the module comprises two covering elements and an insulating layer between said covering elements, and wherein at least one covering element comprises or is as such the heat transfer element.
 8. A module according to claim 7, wherein said insulating layer comprises polyurethane, expanded or extruded polystyrene, polyisocyanurate or mineral wool, such as stone wool or glass wool.
 9. A method for manufacturing a construction module, wherein the module comprises a covering element, the covering element comprising a heat transfer element, wherein the method comprises: providing a heat transfer element by connecting two sheets to each other by multiple connecting seams, and applying high pressure into the space between said connecting seams and said sheets to reform at least one of the sheets to form a conduit with a volume between the sheets and said connecting seams.
 10. A method according to claim 9, wherein said sheets are metal or steel sheets, and the connecting seams are formed by laser beam welding, or wherein said sheets are plastic sheets, and the connecting seams are formed by hot sealing.
 11. A method according to claim 9, wherein the conduits are adjacent to each other and separated from each other only by said connecting seams.
 12. A method according to claim 9, wherein the module comprises two covering elements and an insulating layer between said covering elements, and wherein at least one covering element comprises or is as such the heat transfer element, and wherein the covering elements are arranged and separated from each other by a distance, and the insulating layer is provided, for instance extruded between the covering elements advantageously fastening the covering elements via the insulating layer to each other in order to provide the construction module.
 13. Use of a construction module as a construction module for example in a building, roof, wall, floor or noise barrier, or in base structures of streets, paths and courtyards, wherein said construction module comprises a covering element, said covering element comprising a heat transfer element, and said heat transfer element comprising two sheets connected to each other by multiple connecting seams and said heat transfer element further comprising at least one conduit for a heat transfer medium, where said conduit is defined by said multiple connecting seams between said connecting seams and said sheets.
 14. An arrangement comprising at least one construction module, wherein the arrangement is one of the following: a building, roof, wall, floor or noise barrier, or in base structures of streets, paths and courtyards, wherein said construction module comprises a covering element, said covering element comprising a heat transfer element, and said heat transfer element comprising two sheets connected to each other by multiple connecting seams and said heat transfer element further comprising at least one conduit for a heat transfer medium, where said conduit is defined by said multiple connecting seams between said connecting seams and said sheets.
 15. An arrangement of claim 14, wherein the arrangement comprises a heat transfer medium circulation and controlling means for controlling at least the flow rate and/or flow direction of the heat transfer medium in the conduit of the heat transfer element. 